Samlexpower SEC-1245A Owner's manual

OWNER'S

MANUAL

Please read this

manual BEFORE

operating your

battery charger

Switch Mode,

Automatic, Lead

Acid Battery

Charger

MODELS:

SEC-1250UL

SEC-2425UL

2 | SAMLEX AMERICA INC.

OWNER'S MANUAL: Battery Chargers | Index

SECTION 1: Important Safety Precautions ...................................... 3

SECTION 2: Description & Features ................................................ 5

SECTION 3: Layout .........................................................................6

SECTION 4: Principle of Operation ................................................. 7

SECTION 5: Protections ................................................................ 14

SECTION 6: Installation ................................................................16

SECTION 7: Preparing the Charger for Operation ........................18

SECTION 8: Operation ................................................................ 25

SECTION 9: Troubleshooting ........................................................ 26

SECTION 10: Internal Fuse Ratings .................................................28

SECTION 12: Specications ............................................................ 28

SECTION 13: Warranty ................................................................... 30

DETAILED INFORMATION

For more detailed information, please view White Paper on our

website:

www.samlexamerica.com/support/white-papers

www.samlexamerica.com/support/application_notes

2 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 3

SECTION 1 | Important Safety Precautions

The following safety symbols will be used in this manual to highlight safety

and information:

WARNING!

Indicates possibility of physical harm to the user in case of non-compliance.

!

CAUTION!

Indicates possibility of damage to the equipment in case of non-compliance.

i

INFO

Indicates useful supplemental information.

Hazardous conditions may result if the charger is not installed or operated correctly.

Please read the following instructions to prevent personal injury or damage to the

charger.

BATTERY RELATED

• Toreducetheriskofbatteryexplosion,followtheseinstructionsandthosemarkedon

the battery.

• Neversmokeorallowanopensparkorameinthevicinityofthebatteryorthe

engine.

• ChargeonlyLeadAcidtypeofbatteries(Flooded/AbsorbedGlassMat(AGM)/Gel

Cell).DonotchargeothertypeofbatterieslikeNickelCadmium(NiCad),Nickel-Metal

Hydride(Ni-MH),Dry-Celletc.Othertypesofbatteriesmightburstcausingpersonal

injury.

• Neverchargeafrozenbattery.

• WorkinginthevicinityofLeadAcidbatteriesisdangerous.Batteriesgenerateex-

plosiveHydrogenandOxygengasesduringnormaloperation.Takenecessarysafety

precautions when installing the charger near a battery or in a battery compartment

(Followsafetyinstructionsgivenbythebatterymanufacturer).

• Neverplacethechargerdirectlyaboveorbelowthebatterybeingcharged;gasesor

uidsfromthebatterywillcorrodeanddamagethecharger.Locatethechargerasfar

away from the battery as DC cables permit. Do not install in the same compartment as

batteries.

• Usecautiontoreducetheriskofdroppingametaltoolonthebattery.Itcouldspark

orshortcircuitthebatteryorotherelectricalpartsandcouldcauseanexplosion.

4 | SAMLEX AMERICA INC.

SECTION 1 | Important Safety Precautions

• Removemetalitemslikerings,braceletsandwatcheswhenworkingwithbatteries.

The batteries can produce a short circuit current high enough to weld a ring or the

liketometalandthuscauseasevereburn.

• Ifyouneedtoremoveabattery,alwaysremovethegroundterminalfromthebattery

rst.Makesurethatalltheaccessoriesareoffsothatyoudonotcauseaspark.

CHARGER RELATED

• ThemaximumAhcapacitiesofthebatteriesmustbelimitedasfollows:

- SEC-1250UL: 500Ah

- SEC-2425UL: 300Ah

• Donotoperatethechargerinaclosed-inareaorrestrictventilationinanyway.

Installinawellventilated,cool,dryplace.

• Thechargermustnotbeoperatedinadamporwetenvironment.Whenmounting

inaboat,makesureitisnotsubjectedtobilgewatersplash.

• Donotblocktheventilationopenings/openingsforthecoolingfan.Thereshould

be at least 6 inches clearance all around the unit.

• InstallationandwiringmustcomplywiththelocalandtheNationalElectricalCodes.

It is recommended that installation may be carried out by a certied electrician.

• Wronginstallationonaboatmayleadtocorrosionoftheboat.Itisrecommended

that installation on the boat must be carried out by a boat electrician.

• DisconnecttheACinputpowertothechargerbeforeconnecting/disconnectingthe

batteriesorotherDCloadsorwhenworkingonthecharger.

• DisconnecttheACinputpowerbeforechangingthesettingoftheDipSwitches.

• Thechassisofthechargerisconnectedtotheearthgroundpinofthepowercord

plug.EnsurethattheearthgroundpinofACreceptaclefeedingthechargeris

connected to earth ground.

• Donotuseanadapter.Ifagroundingtypeofreceptacleisnotavailable,donotuse

this charger until proper outlet is installed by a qualied electrician.

• Donotoperatethechargerifthepowercordisdamaged.

4 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 5

SECTION 2 | Description & Features

SEC-1250UL(for12Vbatteries)andSEC-2425UL(for24Vbatteries)arehighcurrent,3

StageChargers(alsocalledIU

O

U)thatdeliver50Aand25Arespectivelyforalmost75%

to80%ofthechargingcycleensuringaveryfast,safeandcompletechargingofLead

Acidbatteries.Thenomenclature“IU

O

U”isaDINnomenclatureandsigniesthe3

chargingstages–“I”forBulkChargeStage,“U

O

”Absorption/Over-chargeStageand

“U”forFloat/MaintenanceStage(underDINspecication,voltageisdesignated“U”

andcurrentisdesignated“I”.Thesubscript“

O

”in“U

O

”signiesover-charge).

FEATURES

• State-of-the-artSwitchModeTechnologyforhighefciency,light-weightandquiet

operation.

• UsercongurableACinputvoltage–120VACor230VAC,50/60Hz

• AutomaticoperationforalltypesofLeadAcidBatteries-Flooded,AGMorGelCell

• Userselectable2or3-StageautomaticchargingalgorithmwithtimedAbsorption

Stageandtemperaturecompensationensuresrapid,safeandfullreturnofcapacity

for stand-alone and loaded batteries.

• Abilitytoreducemaximumchargingcurrenttoapproximately1/2oftheratedcapac-

ityduring“HalfPowerMode”.Thisallowssafechargingoflowercapacitybatteries.

• IncludesaBatteryTemperatureSensorallowingtemperaturecompensatedcharging,

if required.

• 2banksofbatteriescanbechargedsimultaneouslywithouttheuseofanexternal

batteryisolator.Thechargingcurrentwillbesharedbetweenthetwobanksdepend-

ing upon the depth of discharge of the connected batteries.

• VoltmeterandAmmeterformonitoring

• Fancooled-fanON/OFF based on output current.

• Protectionsagainstshortcircuit,overcurrent,reversebatteryconnectionand

over-temperature.

• CanbeusedasapowersupplyorasaDCUPS(UninterruptiblePowerSupply)

when used in conjunction with a battery.

• OptionalRemoteLEDPanelModel900-RCwith10Metersofwireforremote

ON/OFFcontrolandindicationofchargingstatus.

• SafetycertiedandlistedtoULStandardUL-1564

• EMIcomplianttoFCCPart15(B),ClassB

MAXIMUM AH CAPACITY OF BATTERY TO BE CHARGED

Ifthechargersareusedtochargeveryhighcapacitybatteries,theywillbeforcedto

supplytheirmaximumratedchargingcurrentforlongertimethanthedesignedlimit

andhence,thecomponentswillbeoverstressedandarelikelytofailprematurely.To

preventprematurefailure,themaximumAhcapacitiesofthebatteriesmustbelimited

as follows:

- SEC-1250UL:500Ah

- SEC-2425UL:300Ah

6 | SAMLEX AMERICA INC.

SECTION 3 | Layout

NOTE:BothSEC-1250ULandSEC-2425ULhavethesamelayoutanddimensions

Fig. 3.1 Layout of SEC-1250UL and SEC-2425UL

4 5 6 7 8

3 2 1

9

10

11

OUTPUT SIDE

INPUT SIDE

12

13

LEGEND

1. Output connector: +, Bank 1

2. Output connector: +, Bank 2

3. Output connector: –, Common

4. Jack for Temperature Sensor

5. Green LED: Indicates “Half Power

Mode” is ON

6. Jack for optional Remote LED

Panel Model No. 900-RC

7. DIP switches for mode selection

8. Push Switch for Half Power Mode:

Pressed ON; Released OFF

9. Power ON/OFF switch

10. AC power cord inlet

11. Grille protected opening for

cooling fan

12. Voltmeter

13. Ammeter

TOP VIEW

3

2

1

11

10

6 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 7

SECTION 4 | Principle of Operation

i

INFO

Forcompleteunderstandingofworkingofbatterychargers,understandingof

operationofLeadAcidbatteriesisdesirable.

Fordetailedinformationonconstruction,workingandapplicationofbatteries,

pleaserefertoApplicationNotetitled“LeadAcidBatteries–Constructionand

Application”atthefollowinglinktoSamlexAmerica,Inc.website:

www.samlexamerica.com/support/application_notes.aspx

BATTERY CHARGER IS A CURRENT LIMITED DC POWER SUPPLY

ThechargerisacurrentlimitedDCpowersupplythatconverts120/230VAC,50/60Hz

toregulatedDCvoltagesandlimitsthemaximumoutputcurrentasfollows:

Model No. Current Limit

Constant

Voltage at Bulk

Stage “I”

Constant

Voltage at

Absorption

Stage “U

0

”

Constant

Voltage at

Float Stage

“U”

SEC-1250UL 50A 13.5VDC

14.0VDCor

14.4VDC

13.5VDC

SEC-2425UL 25A 27VDC

28.0VDCor

28.8VDC

27VDC

Thespeciedoutputvoltageofthechargerduringparticularchargingstageisheld

constanttillthecurrentlimitvalueisreached.WhenthebatteryorDCloadtriestodraw

current>thecurrentlimitvalue,thechargerlimitsthecurrenttothecurrentlimitvalue

andtheoutputvoltageofthechargerdropsandisnolongerconstant.Whenthechar-

gerisconnectedtoabatteryandisincurrentlimitcondition,theterminalvoltageof

thechargerwillbeclampedtotheactuallowerintrinsicterminalvoltageofthebattery

(assumingthechargerisveryclosetothebatteryandthereisnovoltagedropinthe

wiresconnectionthechargertothebatteries).

BATTERY IMPEDANCE AND CHARGING CURRENT

Theinternalimpedanceofahealthybatteryisverylow-intensofmilliOhms(The

impedance is higher in discharged condition due to Lead Sulfate formation and reduces

whenthebatteryisfullycharged–LeadSulfategetsfullyconvertedtoLeadandLead

Dioxide).Averageimpedancemaybeassumedas20milliOhmor0.02Ohm

Whenthechargerisdeliveringaconstantvoltage(isnotincurrentlimitcondition),the

charging current drawn by the battery can be roughly calculated as follows:

Charging current = (Charger Voltage - Intrinsic battery voltage) ÷ Internal resistance (0.02 Ohm)

8 | SAMLEX AMERICA INC.

SECTION 4 | Principle of Operation

Forexample,whenSEC-1250ULisintheBulkChargeStage1,itsoutputvoltageisset

at13.5VDC.Whenabatterydischargedtosay10.5Vischarged,itwilltrytodrawvery

largecurrent=(13.5V-10.5V)÷Internalresistance(0.02Ω)=150A.SEC-1250ULwill,

however,limitthiscurrentto50A.

CHARGING STAGES

The battery is charged in 3 stages:

• STAGE1-BULKSTAGE(“I”Phase),

• STAGE2-ABSORPTIONSTAGE(“U

O

”Phase)and

• STAGE3-FLOATSTAGE(“U”Phase)

The3chargingstagesandassociatedChargingCurvesforSEC-1250ULaregivenatFig-

ure 4.1 and for SEC-2425UL at Fig. 4.2

Figure 4.1 Charging Curve - SEC-1250UL

* Stage 2 time for 4 or 8 hours.

Voltage

curve

Current

curve

10% of

current

capacity

of charger

(5A ± 0.5A)

80% of

current

capacity

of charger

(40 Amps)

Time, Hours

14.4V

13.5V

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

55

50

45

40

35

30

25

20

15

10

5

0

AMPS VO LT S

Fig xxx - SEC-1250UL Charging Curves (Absorption 14.4V, Float 13.5V)

50A

Stage 1

“I Phase”

Stage 2*

“Uo Phase”

Stage 3

“U Phase”

B1 C1

D1

E1

B2 C2 D2

E2

A1

A2

8 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 9

SECTION 4 | Principle of Operation

Voltage

curve

28.8V

27V

30

28

26

24

22

20

18

16

14

12

10

8

6

4

2

0

27.5

25.0

22.5

20.0

17.5

15.0

12.5

10.0

7.5

5.0

2.5

0

AMPS V O LT S

Fig xxx - SEC-2425UL Charging Curves (Absorption 28.8V, Float 27V)

B1 C1

D1

E1

B2 C2 D2

E2

25A

A1

A2

* Étape 2 temps de 4 ou 8 heures.

10% de la

capacité

actuelle

du chargeur

(3A ± 0,5A)

80% de

la capacité

actuelle du

chargeur

(20 ampères)

Temps, Heures

Étape 1

“Phase I”

Étape 3

“La Phase U”

Étape 2*

“La Phase Uo”

Fig. 4.2 Charging Curve for SEC-2425UL

i

INFO

Please note the following important information related to the Charging Curves

shown in Figs 4.1 and 4.2 above:

1.1 Terminal Voltage reading on no load and on load: The output terminals of the

chargerconsistofonecommonNegativeterminal(3)andtwoRedPositiveterminals

(1,2)forchargingtwobanksofbatteries.EachofthetwoPositiveterminalsofthe

twobankshasSchottkyDiodeinseriesforisolation.Theseisolatingdiodeshavea

currentdependentforwardvoltagedropVfrangingfrom0.2to0.3V(at0.1A)to

0.6V(at50A).Inaddition,therewillbeadditionalforwarddropVbacrossthebulk

resistance of the diode and this drop will also increase with increase in charging

current. Please note that the forward voltage drops Vf and Vb occur only when cur-

rent ows through the diode.

1.2TheFloatandAbsorptionvoltagesaretightlyregulatedbeforetheisolating

diodes.However,thevoltagesavailableattheterminalsofthetwobankswillvary

withthevalueofthechargingcurrentbecauseofthecurrentdependentforward

voltagedropVfandbulkresistancedropVb.TheFloatVoltagebeforethediodesis,

10 | SAMLEX AMERICA INC.

SECTION 4 | Principle of Operation

therefore,set0.2to0.3Vhighertocompensatefortheforwarddropsduringoat

conditionwhenthechargingcurrentwouldhavedroppedtolessthan1A.Hence,

theoutputvoltageattheterminalsofthetwobanksatnoload(nothingconnected

totheterminalsofthebanks)willread0.2to0.3Vhigherbecausethereisnofor-

wardvoltagedropasthereisnocurrentowthroughthediodes.Thevoltagesare

speciedwithrespecttocharging/loadcurrentasfollows:

AbsorptionStage(“U

O

”Phase)of14.4/14VforSEC-1250UL At5A+/-0.5A

AbsorptionStage(“U

O

”Phase)of28.8/28VforSEC-2425UL At3A+/-0.5A

FloatStage(“U”Phase)of13.5VforSEC-1250UL At0.1A

FloatStage(“U”Phase)of13.5VforSEC-2425UL At0.1A

1.3 Pleasealsonotethattheoutputvoltageatthetwobanksmaydifferbetween

0.2to0.6Vdependinguponthedifferentvaluesofthechargingcurrentbeingdeliv-

eredthrougheachasaresultofdifferentvaluesofvoltagedropsVfandVb.

2.1 Standard Temperature Conditions:Thechargingvoltagesshownpertaintobat-

teryelectrolytetemperatureof77°F(25°C)

3.1 Charger / Battery Voltage / Current Values:Whenthebatteryisconnectedto

thechargerandthechargerisinONcondition,thevoltageatthecommoncharger

/batteryterminalswillbetheactualbatteryterminalvoltagecorrespondingtoits

stateofchargeONLYwhenthechargerisin“currentlimitcondition”andissup-

plying50AforSEC-1250ULand25AforSEC-2425UL.WhenthechargerisNOTin

“currentlimit”conditionandissupplying<50AforSEC-1250ULor<25Afor

SEC-2425A,itsterminalvoltagewillbenearlyregulatedandwillbenearlyequalto

thesetBulk/FloatVoltageof13.5VforSEC-1250UL(27VforSEC-2425UL)ornearly

equaltotheAbsorptionVoltageof14.4/14VforSEC-1250UL(28.8V/28VforSEC-

2425UL).Undertheseconditions,thebatteryterminalvoltagewillalsobeat13.5

(27V)or14.4/14V(28.8V/28V)although the actual intrinsic terminal voltage of the

battery corresponding to its State of Charge at that point of time will be lower.

3.2 Thevoltagecurveshowsthevoltageatthechargeroutputterminals,whichwill

bethesameasthevoltageatthebatteryterminals(assumingthatthereisnovolt-

agedropalongthewiresconnectingthechargertothebatteries)

3.3.TheCurrentCurveshowsthecurrentbeingdrawnbythebattery

10 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 11

SECTION 4 | Principle of Operation

STAGE 1- BULK CHARGE STAGE (“I” PHASE)

InthisstageSEC-1250ULoutputsvoltageof13.5VDCandSEC-2425Aoutputs27V.

ThefollowingexplanationisforSEC-1250UL.ExplanationforSEC-2415ULwillbe

samebutthevoltagevalueswillbe2timesandcurrentvalueswillbehalfascompared

to SEC-1250UL.

NOTE: For explanation purpose, it is assumed that the battery is deeply discharged

to around 10.5 / 21V when charging is initiated.

Whenthechargerisswitchedon,thebatterywilltrytodrawverylargecurrent=

(13.5V-10.5V)÷Internalresistance(0.02Ω)=150Awhichwillbemuchhigherthanthe

currentlimitvalueof50A.Thechargerwillentercurrentlimitcondition(pointA2),

itsinternalvoltagewilltrytodropbutwillbeclampedtotheterminalvoltageofthe

batteryi.e.10.5V(pointA1).Thebatterystartschargingatconstantcurrentof50A(Sec-

tionA2-B2)anditsintrinsicvoltagestartsrisingalmostlinearly(SectionA1-B1).When

itsintrinsicvoltageapproaches13.5V,thecurrentdrawnbythebatterywillreduceto

<50A.Atthispoint(B2),thechargerwillexitcurrentlimitandwilloutputaconstant

voltageof13.5V(pointB1).Asthebatterychargesfurtherunderconstantvoltageof

13.5V(SectionB1–C1),itsintrinsicvoltagerisesfurtheranditscurrentstartstotaper

down(SectionB2–C2).Thecurrenttapersdownbecausetheintrinsicbatteryvoltageis

risingandthedifferentialvoltagebetween13.5Vofthechargerandintrinsicvoltageof

thebatteryisreducingthereby,lessercurrentisdrivenintothebattery.Taperingcharge

isprovidedatthistransitiontoreducesurfacechargeeffecttoensurethatthecharge

slowlydiffusestotheinternalthicknessoftheplatesandpreventsovercharging.When

thechargingcurrenttapersdownto80%oftheratedcapacityofthecharger(40Afor

SEC-1250ULand20AforSEC-2425UL)atpoint“B2”,thechargertransitionstothenext

Stage2-AbsorptionBoostStage(“U

O

”Phase)

Charging Characteristics During This Stage Are As Follows:

• Batteryvoltagerisesslowlyandalmostlinearly(itwillstartrisingsharplyat

thebeginningofthenextAbsorptionStage2).

• TheentirechargingcurrentisusedtoconvertLeadSulfatetoSpongeLeadat

theNegativeplatesandtoLeadDioxideatthePositiveplates.

• Thereisnogassingandthechargingefciencyishigh-around91%.

• Therestoredcapacityinthisstageisinverselyproportionaltothechargingrate

(duetoPeukertEffect).Thismeansthatasthechargingrateisincreased,the

capacityrestoredreduces.Thisstagerestores60%ofcapacityatchargingrate

ofC/5,70%to75%capacityatchargingrateofC/10and85%to90%of

capacityatchargingrateofC/20

• RedLEDmarked“IPhase”willbelitontheoptionalRemoteControl

Model900-RC

12 | SAMLEX AMERICA INC.

STAGE 2 – ABSORPTION STAGE (“U

0

” PHASE)

Duringthisstage,thechargeroutputsconstantvoltageof14V/14.4VforSEC-1250UL

and28V/28.8VforSEC-2440UL.Aschargingproceeds,thereisafairlysharpriseinthe

batteryvoltageasgassingstarts.Gassingandfastriseofbatteryvoltagecontinuesto

restore the balance of the capacity till charging is completed.

TheChargerTransitionsToAbsorptionStage(“U

O

”Phase)AtPoint“C”.

Assoonasthechargertransitionstothisstage,auserselectable4Hr/8HrTimeris

startedwiththehelpofDIPSwitches(7)(Seepage22under“Selectingtimeforstage

2-AbsorptionStage”).ThisTimerdecidesthemaximumdurationofoperationinthis

stageandsubsequenttransitiontothenalconstantvoltageFloatStage3atpoint“E”.

The duration of operation in this stage is also determined by another condition where

thetransitiontothenextFloatStageatpoint“E”occurswhenthechargingcurrent

reducesto10%ortheratedcapacityi.e.5A+/-0.5AforSEC-1250ULand3A+/-0.5Afor

SEC-1225UL.Thecondition,whichoccursearlier,controlsthetransition

Atthetransitionpoint“C”,thechargerwilloutputahigherconstantvoltage,whichis

abovetheGassingVoltagetoensurethatthebatteryisfurther,chargedtofullcapacity

withoutovercharging.Thevalueofthisvoltagewilldependuponthetypeofbatteryor

chargingstagesselected(Thetypeofbatteryandchargingstagesareselectedwiththe

helpofDIPSwitches(7)-SeeSection7under“DIPSwitchSetting”onpage21):

• 14.4V(SEC-1250UL)or28.8V(SEC-2425UL)whenFlooded/AGM

battery is selected

• 14V(SEC-1250UL)or28V(SEC-2425UL)whenGelCellbatteryisselected

• 13.5V(SEC-1250UL)or27V(SEC-2425UL)whenloadedbatteryis

selected(2stagecharging)

However,thisconstantvoltageisnotseenimmediatelybecausethechargerenterscur-

rentlimitassoonasitenterspoint(C2).Asthechargervoltagehasbeenincreased,the

batterywilltrytodrawhighervalueofcurrentwhichwillbeequaltothedifference

betweenthishighervoltageandtheactualintrinsicvoltageofthebatterydividedby

theinternalresistanceofthebattery(.02Ohm).Thevalueofthiscurrentatthetransi-

tionpoint(C2)willbehigherthanthecurrentlimitvalueforcingthechargertoenter

currentlimitconditiononceagain.Asthechargerisincurrentlimitcondition,itdoes

notregulateitsoutputvoltage.Thevoltageatthechargerterminalsistheactualinter-

nalbatteryvoltageatthatpoint(C1).Onceagain,thebatterystartschargingfurtherat

themaximumratedconstantcurrentof50AforSEC-1250UL/25AforSEC-2425UL(C2to

D2).Thebatteryvoltagealsostartsrisingfurther(C1toD1).

Atpoint(D2),thechargingcurrentreducestolessthanthecurrentlimitvalueof50A

forSEC-1250UL/25AforSEC-2425ULandthechargernowexitscurrentlimitedconstant

currentmodeandentersconstantvoltagemodeof14V/14.4VforSEC-1250ULand

28V/28.8VforSEC-2440UL(pointD1).(Pleasenotethatthevoltageof14V/14.4Vor

SECTION 4 | Principle of Operation

12 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 13

SECTION 4 | Principle of Operation

28V/28.8VatboththechargerandbatteryterminalsistheconstantAbsorptionVolt-

agebeingputoutbythecharger.Theintrinsicvoltageofthebatteryisstilllowerthan

thisvoltageasthebatteryisstillnotfullychargedatthistransition).Astheintrinsic

voltageofthebatteryrisesfurther,thechargingcurrentstartstaperingdown(section

D2toE2).Taperingchargeisprovidedatthistransitiontoreducesurfacechargeeffect

toensurethatthechargeslowlydiffusestotheinternalthicknessoftheplatesand

preventsovercharging.

Whenthe4Hr/8HrTimerrunsoutorwhenthechargingcurrenttapersdownto10%

oftheratedcapacityofthecharger(5A+/-0.5AforSEC-1250ULand3A+/-0.5AforSEC-

2425UL)atpoint“E2”(whicheverisearlier),thechargertransitionstothenextStage3

-ConstantVoltage,FloatorMaintenanceChargeStage(“U”Phase)

NOTE: Thethresholdofcurrentforchange-overbetweentheConstantOverchargeVolt-

age,TimedVoltageAbsorption/BoostStage(“U0”Phase)&theFloat/Maintenance

ChargeMode(“U”Phase)aredifferentasfollows:

SEC-1250UL SEC-2425UL

 From“Uo”Phaseto“U”Phase 5A+/-0.5A 3A+/-0.5A

 From“U”Phaseto“Uo”Phase 10A+/-1A 6A+/-1A

Charging Characteristics During This Stage Are As Follows:

• TheAbsorptionStage(“U

O

”Phase)feedsadditional35%to55%ofthecapacitythat

addsuptoatotalchargedcapacityofaround115%totakecareofaround15%loss

of charging efciency.

• OrangeLEDmarked“U

O

”PhaseontheoptionalRemoteControl900-RCwillbelit

STAGE 3 - CONSTANT VOLTAGE, FLOAT OR MAINTENANCE

CHARGE STAGE (U PHASE)

Duringthismode,thechargeroutputsaconstantvoltage"U"=13.5V(SEC-1250UL)or

27V(SEC-2425UL).Thishelpsinmaintainingfullcapacityofthebatteryandalsopro-

videsreplacementchargetoovercomeselfdischargeofthebattery.Thebattery

canremainconnectedinthisstageindenitelywithouttheriskofdischarging.

Charging characteristics during this stage are as follows:

GreenLEDmarkedFloatStage(“U”Phase)ontheoptionalRemoteControl

900-RCwillbelit.

14 | SAMLEX AMERICA INC.

SECTION 4 | Principle of Operation

!

CAUTION!

3stagechargingisrecommendedforchargingstand-alone,unloadedbatteries

(thereisnoloadconnectedtothebatterywhenitisbeingcharged).Ifaload

isalsoconnectedsimultaneously,apartofthecharger’soutputcurrentwill

bedivertedtothisload.Thus,thechargermayremainlockedinStage2ifthe

currentdrawnbytheloadismorethanthepresetvalueofthresholdcurrent

determiningchangeoverfromStage2toStage3.Thiswillleadtoover-charg-

ing and loss of electrolyte.

Forchargingabatterywhenaloadisalsoconnectedsimultaneously,Stage2

voltageshouldbesameasStage3.Select“LoadedBattery”withthehelpof

DIPSwitchesmarked“Mode”(7)-SeeSection7under“DIPSwitchSetting”on

page 21.

SECTION 5 | Protections

The charger has the following protections:

SHORT CIRCUIT SHUT DOWN

Incaseofashortcircuitontheoutputside,theoutputofthechargerwillbeshutdown.

AnothersymptomofshortcircuitshutdownisthatthefanwillbeONtilltheunitis

resetorswitchedOFF.OntheoptionalRemoteControl900-RC,GreenLEDmarked

"Power"andRedLED"IPhase"willbelit.Thechargerwillbelatchedinthisshutdown

conditionandwillNOTrecoverautomaticallyevenaftertheshortcircuitconditionis

removed.Toreset,theACinputpowerON/OFFswitchatthebackoftheunithastobe

switchedOFFandONagain.

OVER LOAD CURRENT LIMITING

Thecurrentdrawnbytheloadisautomaticallylimitedtoamaximumof50Afor

SEC-1250UL(25A+/-1Ain“HalfPowerMode”)and2AforSEC-2425UL(12.5A+/-1A

whenin“HalfPowerMode”).Iftheloadtriestodrawahighercurrentthantheselim-

its,theoutputvoltageoftheunitwillstarttodrop.Theunitwillautomaticallyrecover

whentheoverloadconditionisremoved.

REVERSE BATTERY CONNECTION – DC SIDE FUSES WILL BLOW

TheoutputisinternallyfusedontheDCside-2x30AfusesforSEC-1250ULand2X

20AfusesforSEC-2425UL.Incase,thepolarityofthebatteryconnectionisreversed,the

fuse(s)willblow.AnothersymptomofblownfuseonDCsideisthatthefanwillbeON

tilltheunitisswitchedOFF.OntheoptionalRemoteControl900-RC,GreenLEDmarked

"Power"andRedLEDmarked"IPhase"willbelit.

14 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 15

SECTION 5 | Protections

COOLING

Thechargeriscooledbyconvectionandinaddition,hasafanforforcedair-cooling.

The operation of the fan is controlled by the current supplied by the charger and will be

switchedONandOFFautomaticallyasfollows:

SEC-1250UL SEC-2425UL

SwitchONcurrent 10A+/-1A 6A+/-1A

Switch OFF current 5A+/-0.5A 3A+/-0.5A

NOTE:Oncethefanswitchesonatthespeciedcurrentthreshold,itwillswitchoffat

alowerthreshold.Forexample,thefaninSEC-1250ULswitchesONat10Abutswitches

OFFat5A.ThisistopreventthefanfromoscillatingbetweenONandOFFconditions

duetominoructuationsinloadcurrent

OVER TEMPERATURE SHUTDOWN

!

CAUTION!

Keepthechargerinawellventilated,coolandopenarea.DONOTBLOCKTHE

VENTHOLESonthesidesorthedischargeopeningsofthecoolingfan.Keepat

least 6” clearance on all sides

In case the fan fails or if the cooling is not adequate due to higher ambient tempera-

ture,inadequateaircirculationorblockageofairventilationopenings,thetemperature

insidetheunitwillrise.Atemperaturesensorismountedoninthewindingsofthe

powertransformer.At105°C+/-5°Cthethermalsensorwillactivateandshutdownthe

outputvoltageofthecharger.ThefanwillbeON.OntheoptionalRemoteControl

900-RC,GreenLEDmarked"Power"andRedLEDmarked"IPhase"willbelit.The

chargerwillbelatchedinthisshutdownconditionandwillNOTresetautomatically

evenaftertheunithascooleddown.Toreset,theACinputpowerON/OFFswitchatthe

backoftheunithastobeswitchedOFFandONagain.

PROTECTION AGAINST TRANSIENTS / SURGES IN THE AC INPUT

Inanumberoflocations,theAClineinputisnotcleanandmaycontainhighvolt-

agetransients/surges.Topreventdamagetotheinternalcomponentsagainstthese

unwantedhighvoltages,thechargerusesaMOV(MetalOxideVaristor)forprotection.

Ifsurge/transientvoltagehigherthanapproximately170VACin120VMode/340VAC

in230VACModeappearintheACinput,theMOVwillconductandwillblowtheAC

side fuse.

16 | SAMLEX AMERICA INC.

SECTION 6 | Installation

INSTALLATION DIMENSIONS

Installationdimensionsaregivenbelow.DimensionsaresameforSEC-1250ULand

SEC-2425UL.

16 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 17

SECTION 6 | Installation

LOCATION, MOUNTING AND SAFETY

Thechargerisrequiredtobeinstalledinasafe,wellventilatedanddrylocation.

Pleaseseethedetailsgivenunder“ImportantSafetyPrecautions”.Thechargercanbe

mountedhorizontallyorvertically.Whenmountingverticallyonawallorabulkhead,

pleaseensurethattheaxisofthefanrotorishorizontali.e.thefanexhaustopening

shouldfaceleftorrightbutNOTfaceupordown.

WARNING!

Mountingtheunitverticallyonaverticalsurfacewiththefanopeningfacing

upordownisNOTallowedforsafety.Thisistopreventfallingofobjectsinto

the unit through the fan grille when the fan opening faces up. If fan opening

facesdown,hotdamagedcomponentsmayfallout.

OUTPUT CONNECTORS

Connectorswithtubular,screwdowntypeofterminalsareusedforoutputconnection.

Thediameterofthetubularholeoftheconnectoris8mm(0.31inches).Twopositive

outputconnectors(1,2)areprovidedforconnectingtothePositiveterminalsofthe2

banksofbatteries.Onecommonconnector(3)isprovidedfortheNegative

connection.

TERMINAL LUGS FOR CONNECTION TO THE CHARGER

Forrmconnectionwhenusingstrandedwire,crimp/solder“pin”styleterminallugs

onthechargerendoftheDCwiresusedforconnectingtothebattery/otherDCloads.

3piecesof“pin”styleterminallugshavebeenprovidedasfollows:

• ForSEC-1250UL WillaccommodateuptoAWG#4wire

• ForSEC-2425UL WillaccommodateuptoAWG#8wire

WIRES

Toavoidpolarityerrorsandpossibledamage,neverusewiresofonlyonecolor.UseRed

insulatedwire(s)forPositiveconnection(s)andBlackforNegativeconnection(s).

RecommendedDCwiresizesaregivenbelow(Basedonavoltagedropof2%).The

lengthinfeetisthelengthofthepairofthepositiveandnegativeDCwiresfromthe

chargertothebattery/otherDCloads.

Distance From Battery SEC-1250UL SEC-2425UL

Up to 6 ft. AWG#6 AWG#10

6 to 10 ft AWG#4 AWG#8

10 to 20 ft. AWG#1/0 AWG#6

TERMINATION OF WIRE ENDS

Forrmconnectionwhenusingstrandedwire,wireendsfortheconnectiontothe

chargershouldbeterminatedwithpintypesoflugsthathavebeenprovided.

18 | SAMLEX AMERICA INC.

SELECTING AC INPUT VOLTAGE

Thechargerispre-settooperatefrominputACvoltageof120VAC,60Hz.Tooperate

thechargerfromACinputvoltageof230VAC,50Hz,changetheinternalsettingas

follows:

1.Removethesideplatethathasthepowercordentrybyunscrewing4screws

2.RemovetheVoltmeterandtheAmmeteronthetopcentralplatebypryingupthe

bottomedgesofthemeterswithabroad,atscrewdriverandbypushingthemeters

upfromthebottomoftheplate(thesearesnaptted).Removetheconnectingwires

andmarkthem.Notethepolarityforconnectingbackinproperpolarity.Themeter

terminalsaremarkedPositive(+)andNegative(-).ThickerwiresarefortheAmmeter

andthinnerarefortheVoltmeter

3.Gentlyslidethecentertopcoverplateout.Noteandmarkitsorientationfor

correct re-tting

4.LocateYellowloopofjumperwirewithquickfemaledisconnect.Inthepre-set

120VACcondition,thisjumperwireisshortingthemaleverticalpinsmarked“C”and

“D”and“115V”.Pullanyoneendofthisfemaledisconnectupwardstodisconnect

shortingbetween“C”and“D”.Insulatethisendwithinsulatingtape.Theunitisnow

setfor“230VAC”

5.The120VACversionhasasoldered12AfuseontheACside.Whenconverting

120VACversionunitfor230VACoperation,thereisnoneedtoreplacethe12Afuse

6.ReplacetheACplugofthepowercordwithasuitable3pingroundedplugtomate

withthe230VACoutlet.

!

CAUTION!

Thenewplugshouldhave3polesi.e.Line(L),Neutral(N)andEarthground.

Color code for the power cord conductors is:

- Line(L)-Black

- Neutral(N)-White

- Earthground-Green

CONNECTING THE BATTERIES OR OTHER DC LOADS

AsshowninFig.7.1and7.2(page19),theoutputofthechargerhasacommonNega-

tive(-)connectorand2Positiveconnectorsforconnectionof2banksofbatteries.Each

Positiveconnectorhasitsowninternalisolatingdiode,whichworksasabatteryisolator.

Ifmorethanonebankofbatteriesisconnected,thesewillbechargedatthesametime

aslongastheACpowerisavailabletothecharger(themaximumchargingcurrentof

50AofSEC-1250ULand25AofSEC-2425ULwillbesharedamongtheconnectedbanks

ofthebatteriesdependingupontheirdischargedstates).IncasetheACpowerfails

orifthereisnooutputfromthecharger,theisolatingdiodeswillpreventcharging/

dischargingamongthebatteriesconnectedtothebanks.

SECTION 7 | Preparing the Charger for Operation

18 | SAMLEX AMERICA INC. SAMLEX AMERICA INC. | 19

SECTION 7 | Preparing the Charger for Operation

Starter

Battery

Auxilary /

House

Battery

Battery 4 Battery 3 Battery 2 Battery 1

Negative

Wire “B”

Positive

Wire “A”

Fig 7.1 Connecting 2 separate battery systems to 2 separate banks

Fig. 7.2 Connecting bank of paralleled batteries to single bank

20 | SAMLEX AMERICA INC.

Inasinglebatterybank,twoormorebatteriesmaybeconnectedinparalleltoincrease

theirAHcapacity.Thesewillbedischargedandchargedasasinglebatterybank.Inthis

case,theparalleledbankofmultiplebatteriesistobeconsideredasasinglebankand

connectedtoanyoneofthe2banksofthechargerasshowninFig.7.2forbankof4

batteries.Forproperchargingofallthebatteries,pleaseensurethatthePositivewire

“A”fromthechargerisconnectedtothePositiveterminaloftherstbattery(Battery

1)andtheNegativewire“B”isconnectedtotheNegativeterminalofthelastbattery

(Battery4).Thiswillensurethefollowing:

• Resistanceoftheinterconnectingcableswillbebalancedandtheindividualbatteries

will see the same series resistance

• Alltheindividualbatterieswillbechargedatthesamechargingcurrentandthuswill

be charged to the same state of charge

• Noneofthebatterieswillseeanover-chargecondition

WhenconnectingasinglebatteryorothersingleDCload,itcanbeconnectedtothe

commonNegativeandanyoneofthe2PositiveterminalsasinFig.7.1.

CHARGING MORE THAN ONE BANK OF BATTERIES

!

CAUTION!

Whenchargingmorethanonebankofbatteriesatthesametimeusing3Stage

Charging,ensurethatthebatteriesinthebanksareinasimilardischargedcon-

dition.Ifonebankiscompletelydischargedandanotherisalmostfullycharged,

thebankthatisfullychargedwillbesubjectedtooverchargeconditionduring

thetimewhenthechargerremainsinStage2(“Uo”Phase)forchargingthe

completelydischargedbank.

If2banksofbatteriesarerequiredtobechargedandtheyareatdifferent

dischargedconditions,select“LoadedBattery”(2StageCharging)withthehelp

ofswitchesS1andS2ofthesetof4DIPSwitches(bothS1&S2inoffcondition)

-Seeunderheading“DipSwitchSetting”onpage21.

SELECTING TYPE OF BATTERY AND CHARGING STAGES

Stage3FloatStage(“U”Phase)voltageandStage2AbsorptionStage(“Uo”Phase)volt-

agearedifferentfordifferenttypesofLeadAcidBatteries.

3Stagecharging(Stages1,2and3)isrecommendedwhenchargingstandalone,un-

loadedbattery(Thebatteryhasnoloadconnectedtoitwhenitisbeingcharged).

Whenthechargerisusedtochargeabatteryandsimultaneouslysupplyanexternal

load,thevoltagelevelofStage2isrequiredtobesettothesamelevelasthevoltageof

Stage3topreventover-charging.Effectively,thebatterywillbechargedin2stagesonly

SECTION 7 | Preparing the Charger for Operation

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Samlexpower SEC-1245A Owner's manual

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